Index Manuals SANY Crawler Hydraulic Excavator SY215CLC (CUMMINS QSB6.7 engine). Shop Manual

SANY Crawler Hydraulic Excavator SY215CLC (CUMMINS QSB6.7 engine). Shop Manual - page 3

Introduction

SY215C

1-18

4. Repair limit and allowable value

●

The size of a part changes due to wear
and deformation while it is used. The limit
of changed size is called the "repair limit".

●

If a part is worn to the repair limit must be
replaced or repaired.

●

The performance and function of a product
lowers while it is used. A value below which
the product can be used without causing a
problem is called the "allowable value".

●

If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.

5. Clearance limit

●

Parts can be used until the clearance be-
tween them is increased to a certain limit.
The limit at which those parts cannot be
used is called the "clearance limit".

●

If the clearance between the parts exceeds
the clearance limit, they must be replaced
or repaired.

6. Interference limit

●

The allowable maximum interference be-
tween the hole of a part and the shaft of
another part to be assembled is called the
"interference limit".

●

The interference limit shows the repair limit
of the part of smaller tolerance.

●

If the interference between the parts ex-
ceeds the interference limit, they must be
replaced or repaired.

Introduction

SY215C

1-19

1.4

Handling Electrical and Hydraulic Components

To maintain the performance of the machine
over a long period, and to prevent failures or
other troubles before they occur, correct "oper-
ation", "maintenance and inspection", "trouble-
shooting", and "repairs" must be carried out.
This section deals particularly with correct re-
pair procedures for mechatronics and is aimed
at improving the quality of repairs. For this
purpose, it gives sections on "Handling electric
components" and "Handling hydraulic equip-
ment" (particularly gear oil and hydraulic oil).

1.4.1 Points to remember when handling electric components

ZX215-1000004

1. Handling wiring harnesses and connec-

tors

Wiring harnesses consist of wiring con-
necting one component to another compo-
nent, connectors used for connecting and
disconnecting one wire from another wire,
and protectors or tubes used for protecting
the wiring.

Compared with other electrical compo-
nents fitted in boxes or cases, wiring
harnesses are more likely to be affected
by the direct effects of rain, water, heat, or
vibration. Furthermore, during inspection
and repair operations, they are frequently
removed and installed again, so they are
likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling wiring harnesses.

Introduction

SY215C

1-20

Improper insertion

ZX215-1000005

ZX215-1000006

Crimped portion

ZX215-1000007

3) Disconnections in wiring

If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.

2. Main failures occurring in wiring har-

ness

1) Defective contact of connectors (defective

contact between male and female)

Problems with defective contact are likely
to occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors
is deformed or the position is not correctly
aligned, or because there is corrosion or
oxidation of the contact surfaces.

2) Defective crimping or soldering of connec-

tors

The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.

Introduction

SY215C

1-21

4) High-pressure water entering connector

The connector is designed to make it
difficult for water to enter (drip-proof
structure), but if high-pressure water is
sprayed directly on the connector, water
may enter the connector, depending on the
direction of the water jet. Accordingly, take
care not splash water over the connector.
The connector is designed to prevent
water from entering, but at the same time,
if water does enter, it is difficult for it to
be drained. Therefore, if water should get
into the connector, the pins will be short-
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing
electricity through it.

ZX215-1000008

5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating
surface between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe
it off with a dry cloth or blow it dry with
compressed air and spray it with a contact
restorer.

★

When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.

★

If there is oil or water in the compressed
air, the contacts will become even
dirtier, so remove the oil and water from
the compressed air completely before
cleaning with compressed air.

ZX215-1000009

Introduction

SY215C

1-22

3. Removing, installing, and drying con-

nectors and wiring harnesses

1) Disconnecting connectors

a. Hold the connectors when disconnect-

ing.

When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull apart.
For connectors which have a lock stop-
per, press down the stopper with your
thumb and pull the connectors apart.

★

Never pull with one hand.

b. When removing from clips

●

Both of the connector and clip have
stoppers, which are engaged with each
other when the connector is installed.

ZX215-1000010

Press lightly

when removing

Lock stopper

ZX215-1000011

Both stoppers

●

When removing a connector from a clip,
pull the connector in a parallel direction
to the clip for removing stoppers.

★

If the connector is twisted up and
down or to the left or right, the hous-
ing may break.

ZX215-1000012

Introduction

SY215C

1-23

c. Action to take after removing connec-

tors

After removing any connector, cover
it with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.

★

If the machine is left disassembled for

a long time, it is particularly easy for
improper contact to occur, so always
cover the connector.

ZX215-1000013

ZX215-1000021

Clicks into position

2) Connecting connectors

a. Check the connector visually

Check that there is no oil, dirt, or water
stuck to the connector pins (mating
portion).

Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.

Check that there is no damage or
breakage to the outside of the connec-
tor.

★

If there is any oil, water, or dirt stuck

to the connector, wipe it off with a
dry cloth. If any water has got inside
the connector, warm the inside of the
wiring with a dryer, but be careful not
to make it too hot as this will cause
short circuits.

★

If there is any damage or breakage,

replace the connector.

Introduction

SY215C

1-24

3) Connecting DT connectors

Since the DT 8-pin and 12-pin heavy duty
wire connectors have 2 latches respec-
tively, push them in until they click 2 times.

●

Male connector: 1

●

Female connector: 2

●

Normal locking state (Horizontal): a, b,
d

●

Incomplete locking state (Diagonal): c

ZX215-1000015

ZX215-1000016

b. Fix the connector securely.

Align the position of the connector
correctly, and then insert it securely.
For connectors with lock stopper, push
in the connector until the stopper clicks
into position.

c. Correct any protrusion of the boot and

any misalignment of the wiring harness.

For connectors

tted with boots, correct

any protrusion of the boot. In addition, if
the wiring harness is misaligned, or the
clamp is out of position, adjust it to its
correct position.

★

If the connector cannot be corrected

easily, remove the clamp and adjust
the position.

●

If the connector clamp has been re-
moved, be sure to return it to its origi-
nal position. Check also that there are
no loose clamps.

ZX215-1000014

Introduction

SY215C

1-25

4) Drying wiring harness

If there is any oil or dirt on the wiring
harness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do not
use high-pressure water or steam directly
on the wiring harness. If water gets directly
on the connector, do as follows.

a. Disconnect the connector and wipe off

the water with a dry cloth.

★

If the connector is blown dry with
compressed air, there is the risk that oil
in the air may cause defective contact,
so remove all oil and water from the
compressed air before blowing with air.

b. Dry the connector with a dryer.

If water gets inside the connector, use
a dryer to dry the connector.

★

Hot air from the dryer can be used,

but regulate the time that the hot air
is used in order not to make the con-
nector or related parts too hot, as this
will cause deformation or damage to
the connector.

c. Carry out a continuity test on the con-

nector.

After drying, leave the wiring harness
disconnected and carry out a continuity
test to check for any short circuits
between pins caused by water.

★

After completely drying the connector,

blow it with contact restorer and reas-
semble.

ZX215-1000018

T adapter

ZX215-1000017

ZX215-1000009

Introduction

SY215C

1-26

ZX215-1000021

4. Handling the integrated control monitor

1) The integrated control monitor contains a

microcomputer, an electronic control cir-
cuits, an LCD monitor and GPS positioning
circuit. They control all of the electronic
circuits on the machine, so be extremely
careful when handling the integrated con-
trol monitor.

2) Do not place objects on the integrated con-

trol monitor.

3) Cover the control connectors with tape or a

vinyl bag. Never touch the connector con-
tacts with your hand.

4) Do not leave it where it may be exposed to

rain.

5) Do not place the integrated control moni-

tor on oil, water, or soil, or in any hot place,
even for a short time.

6) Precautions for arc welding

When welding on the controller, disconnect
all wiring harness connectors connected
to the controller. Fit an arc welding ground
close to the welding point.

ZX215-1000019

ZX215-1000020

Tool Box

Introduction

SY215C

1-27

5. Points to remember when troubleshoot-

ing electric circuits

1) Always turn the power OFF before discon-

necting or connecting connectors.

2) Before carrying out troubleshooting, check

that all the related connectors are properly
inserted.

★

Disconnect and connect the related
connectors several times to check.

3) Always connect any disconnected connec-

tors before going on to the next step.

★

If the power is turned ON with the con-
nectors still disconnected, unnecessary
abnormality displays will be generated.

4) When carrying out troubleshooting of cir-

cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.

★

If there is any change, there is probably
defective contact in that circuit.

Introduction

SY215C

1-28

1.4.2 Points to remember when handling hydraulic equipment

1. Be careful of the operating environment

Avoid adding hydraulic oil, replacing

lters,

or repairing the machine in rain or high
winds, or places where there is a lot of
dust.

2. Disassembly and maintenance work in

the fi eld

If disassembly or maintenance work is
carried out on hydraulic equipment in the
field, there is danger of dust entering the
equipment. It is also difficult to check the
performance after repairs, so it is desir-
able to use unit exchange. Disassembly
and maintenance of hydraulic equipment
should be carried out in a specially pre-
pared dust-proof workshop, and the perfor-
mance should be checked with special test
equipment.

3. Sealing openings

After any piping or equipment is removed,
the openings should be sealed with caps,
tapes, or vinyl bags to prevent any dirt or
dust from entering. If the opening is left
open or is blocked with a rag, there is
danger of dirt entering or of the surround-
ing area being made dirty by leaking oil so
never do this. Do not simply drain oil out
onto the ground, but collect it and ask the
customer to dispose of it, or take it back
with you for disposal.

ZX215-1000023

ZX215-1000024

With the increase in pressure and precision
of hydraulic equipment, the most common
cause of failure is dirt (foreign material) in the
hydraulic circuit. When adding hydraulic oil, or
when disassembling or assembling hydraulic
equipment, it is necessary to be particularly
careful.

Introduction

SY215C

1-29

4. Do not let any dirt or dust get in during

refi lling operations

Be careful not to let any dirt or dust get
in when refilling with hydraulic oil. Always
keep the oil filler and the area around it
clean, and also use clean pumps and oil
containers. If an oil cleaning device is
used, it is possible to

lter out the dirt that

has collected during storage, so this is an
even more effective method.

ZX215-1000025

5. Change hydraulic oil when the tempera-

ture is high

When hydraulic oil or other oil is warm, it
flows easily. In addition, the sludge can
also be drained out easily from the circuit
together with the oil, so it is best to change
the oil when it is still warm. When changing
the oil, as much as possible of the old
hydraulic oil must be drained out. (Drain
the oil from the hydraulic tank; also drain
the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the
contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.

6. Flushing operations

After disassembling and assembling the
equipment, or changing the oil, use

ush-

ing oil to remove the contaminants, sludge,
and old oil from the hydraulic circuit.
Normally, flushing is carried out twice:
primary

ushing is carried out with

ushing

oil, and secondary flushing is carried out
with the speci

ed hydraulic oil.

ZX215-1000026

Flushing oil

Introduction

SY215C

1-30

7. Cleaning operations

After repairing the hydraulic equipment
(pump, control valve, etc.) or when run-
ning the machine, carry out oil cleaning
to remove the sludge or contaminants in
the hydraulic oil circuit. The oil cleaning
equipment is used to remove the ultra

(about 3

) particles that the filter built in

the hydraulic equipment cannot remove, so
it is an extremely effective device.

ZX215-1000027

1.5

Hose Connector

Hose connector is used to connect hoses with
a small diameter. The metal sealing surface (4)
of the joint (1) must be in close contact with
the metal sealing surface (5) of the hose (2) to
seal pressurized oil.

●

Do not over-tighten the nut (3). Exces-
sive force applied on the metal sealing
surface (4) and (5) may cause the joint
(1) to break. Be sure to tighten nut (3)
according to technical specifi cations.

●

Scratches or other damages on seal-
ing surface (4) and (5) may cause leaks
at the joint. Be extremely careful not
to damage the sealing surfaces during
connecting and disconnecting work.

ZX215-1000028

Connector

NOTICE

Introduction

SY215C

1-31

1.5.1 Type of hose connector

ZX215-1000029

Female

Male

Type

Wrench size mm

Tightening torque

Connecting nut

Hose joint

N·m(kgf·m,Ibf·ft)

24° Male

59(6,44)

98(10,72)

118(12,87)

235(24,173)

295(30,218)

490(50,361)

670(68,494)

980(100,723)

24° Female

44(4.5,32)

59(6,44)

118(12,87)

30, 32

235(24,173)

295(30,218)

490(50,361)

1.5.2 Hose connector tightening torque table

●

The torque values listed in the table are
intended for general application.

●

Do not use torque values listed in this
table when different torque values are
specifi ed for a special purpose.

NOTICE

Introduction

SY215C

1-32

Place O-ring (6) in contact with the contact
surface of the joint (7) to seal the pressurized
oil.

1.5.3 Connection of O-rings

Wrench size mm

Tightening torque

Connecting nut

Hose joint

N·m (kgf·m,Ibf·ft)

44(4.5,32)

59(6,44)

118(12,87)

30, 32

235(24,173)

295(30,218)

490(50,361)

●

Replace o-rings (6) with new ones
when re-connecting hoses.

●

Before tightening nut (9), make sure the
o-ring (6) has been placed into the o-
ring seat (8).Displacement of the o-ring
may have it damaged and cause leaks.

●

Be careful not to damage the o-ring
seat (8) or the sealing surface (10).
Damaged o-ring (6) may cause oil leak-
age.

●

If oil leakage due to loosened nut (9) is
detected, do not try to stop the leakage
by tightening nut (9). Instead, replace
o-ring (6) with a new one and make
sure it is well positioned, and tighten
nut (9).

ZX215-1000030

Hose connector

NOTICE

Introduction

SY215C

1-33

1.6

Table of Standard Tightening Torques

Bolt

diameter

Bolt

grade

Wrench

size

Hex wrench

size

Hexagonal bolt

Hexagonal socket head bolt

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

10.9

13.2

1.37

9.74

13.2

1.37

9.74

10.9

3.16

22.87

3.16

22.87

M10

10.9

6.73

48.7

6.73

48.7

M12

10.9

113

11.53

83.39

113

11.53

83.39

M14

10.9

177

18.06

130.6

177

18.06

130.6

M16

10.9

279

28.47

205.9

279

28.47

205.9

M18

10.9

382

38.98

281.9

382

38.98

281.9

M20

10.9

549

56.02

405.16

549

56.02

405.16

M27

10.9

1320

134.7

974.16

1320

134.7

974.16

M10

12.9

7.96

57.76

7.96

57.76

M12

12.9

137

13.98

101.1

137

13.98

101.1

M16

12.9

339

34.6

250.18

339

34.6

250.18

M20

12.9

664

67.75

490

664

67.75

490

The following items apply to fi ne thread and coarse thread.

●

Apply grease (zinc white B dissolved in spindle oil) onto the nuts and bolts to reduce
the friction coeffi cient. Thrust bolts do not require greasing.

●

Torque tolerance is ±10%.

●

Always use bolts of correct length. The tip of bolts with excessive length may contact
the bottom of the bolt hole, resulting in under-tightening. Bolts with inadequate length
may result in insuffi cient fastening.

●

The torque values listed in the table are intended for general application. If different
torque values are specifi ed for a special purpose, the torque values in this table are
not applicable any more.

●

Make sure the threads are free of dirt or rusts before installation of nuts and bolts.

Table of tightening torques for bolts and nuts

★

Unless speci

ed otherwise, tighten metric nuts and bolts to the torque below. (When using

torque wrench)

NOTICE

Content .. 1 2 3 4 ..